Personal Device Charging Cable – 2-Pin Magnetic ODM

Overview

A personal device charging cable is the dedicated charging lead that ships with a compact rechargeable product rather than a cable the user buys separately. Our version is a 1 m USB-A to two-pin magnetic pogo lead built for volume ODM programs, with a fuse embedded inside the USB-A plug and a molded head that snaps onto the device contacts. It is specified for rechargeable personal care and wellness devices: handheld, body-contact products with sealed housings, daily charging cycles and cleaning between uses. Indicatively, that reference build is about US$0.40 per unit at 10,000 pieces FOB, confirm per RFQ. This page covers why this category needs a dedicated lead, how the magnetic interface is matched, what the material and compliance package looks like, and how the unit cost is assembled.

What a Personal Device Charging Cable Includes

The assembly has three functional parts. A USB-A male plug connects to any standard USB power source and carries the embedded fuse. A round jacketed lead carries the charging current. A two-pin magnetic head at the far end holds two pogo contacts between two permanent magnets and seats on the device without a plug-in port. Because the device housing stays sealed, designers avoid a cavity that would otherwise need a gasket, a drainage path and a corrosion-resistant contact area. The USB end follows the specifications published by the USB Implementers Forum; the magnetic head is built to the mating drawing or an approved sample. A personal device charging cable is therefore specified from the device side first, not selected from a cable catalog. We treat the lead as part of the product, not as an accessory, because it ships in the same box and is judged by the same field return rate.

Why This Category Needs a Dedicated Charging Lead

Rechargeable personal care and wellness devices share a set of constraints that a generic phone cable does not meet. They are small, so the head must be compact and low profile. They are sealed and often water-resistant, so an open port is a liability. They are held against the skin and wiped down, so jacket compounds, overmold smoothness and the absence of sharp edges matter. They are charged frequently, sometimes unattended, so the connection must be forgiving of misalignment and tolerant of a sideways pull. A magnetic head answers most of these at once: it self-aligns, releases under a tug, needs no opening in the housing and presents a smooth wipeable face. The remaining risk is electrical, which is why the supply lead carries its own overcurrent protection rather than relying solely on the device.

Personal Device Charging Cable Specifications

The table below is the reference configuration behind the indicative price. It is a starting point for a quote, not a fixed catalog part: head geometry, pin assignment, fuse rating and jacket compound are all set on the approved drawing.

Magnetic Head Shapes and Device Matching

The head has to match the device, and the shape is part of that match. We have tooled round puck, teardrop, triangular fan, heart or kidney profile, and a puck designed to sit in a holder base for this series. Two-pin versions carry power only; the polarity is fixed in writing so a reversed assignment cannot damage the product. Pitch, pin diameter, magnet polarity and the housing outline are measured from the device contact drawing, a physical sample of the current charger, or the device itself. Do not order from pitch alone: two heads can share a pitch and still fail to seat because the magnet positions differ. Where a program spans several models, we can key the heads differently so the wrong lead cannot be attached, or standardize on one head across models to keep the unit price down. Sending the sample is always the fastest route to a matched first article.

Overcurrent Protection Inside the USB-A Plug

The fuse is embedded in the overmolded USB-A male plug housing, so from the outside the connector looks like a standard USB-A plug. There is no inline fuse holder, no cylindrical bulge on the cable and no extra box to lose. Hiding the protection inside the plug keeps the lead smooth, wipeable and free of a snag point, which matters for a product that is cleaned and handled daily. It also keeps the magnetic head at the small size the device requires. A magnetic head can land on keys, a coin or a metal table edge while live, and a crushed jacket or worn strain relief can create an internal fault; the fuse opens the circuit before that fault delivers damaging energy. It is a standard part of this series, independent of the battery management inside the device. Its rating, breaking characteristics and any related approvals are set per project on the drawing and are confirm per build. The fuse is a built-in part of this series. Its rating, breaking characteristics and any related approvals are set per project on the approved drawing and are confirm per build; we do not publish a generic rating that would be wrong for half the programs we quote.

Body-Contact Materials and Proposition 65 Compliance

Jacket and overmold compounds are chosen for repeated skin contact and routine cleaning. Standard builds use stranded copper in a PVC or TPE jacket with a smooth molded strain relief and a head overmold with no sharp edges or parting-line flash. Where a device is wiped with alcohol-based cleaners or stored in a humid bathroom, we quote a compound with better chemical and hydrolysis resistance and confirm the choice against the cleaning agent in writing. Jacket color is matched to the device or the retail box; a softer-touch or braided finish is quoted as a separate line. Head geometry is kept free of recesses that trap residue, and the pogo contacts are plated so they resist corrosion from moisture and cleaning residue. These are small details, but they are the ones that show up as warranty returns six months after launch rather than on the production line.

For products that contact the body, buyers usually ask for material declarations before they ask for a price. Material compliance documentation for this series, including California Proposition 65 testing for lead and phthalates, is available on request. RoHS and REACH documentation for the destination market can be assembled alongside it. We do not claim that a certificate covers a build that has not been tested: coverage is matched to the exact compound, color, plating and head geometry of the order and confirmed in writing before production. If your market requires a specific warning label or a declaration in the retail box, send the artwork early, because a late label change can hold a finished lot in the warehouse. Ask for the package in the RFQ so the quote includes the engineering time.

Indicative Volume Pricing

The reference 1 m build is indicatively about US$0.40 per unit at 10,000 pieces FOB. From that baseline, four changes move the number: a different fuse rating or a resettable type adds component and validation cost, a new head geometry adds a tooling charge, a longer or heavier-gauge cable adds copper, and retail packaging adds printing and labor. A protection IC in the head is a separate quoted option, not a substitute for the fuse in the plug. We publish the reference point so the trade-offs are visible, then confirm the final figure in writing. All prices on this page are indicative, quoted FOB, and must be confirmed per RFQ. Unit price varies with connector, length, jacket, packaging, tooling and the compliance documentation required for the destination market. Fuse ratings and test limits are specified on the drawing and confirmed in writing before production.

Market Price Context

A survey of publicly listed prices in October 2026 found single magnetic charging cables at roughly US$2.20 to US$5.00 in retail listings, and roughly US$0.45 to US$3.00 each in B2B supplier listings at minimum order quantities of 1,000 to 5,000 pieces. The lowest published B2B tier we found was around US$0.45 at 5,000 pieces. Our indicative US$0.40 at 10,000 pieces undercuts those published tiers because the program is priced on volume and tooling reuse, not on a catalog margin. These figures are observations of public listings at a point in time, not offers, and they vary with specification and packaging. Few of those listings include an embedded fuse, so use them as context rather than as a like-for-like benchmark.

Custom Lengths, Colors and ODM Programs

Length is cut to order; 1 m is the common charging-lead length and the basis of the reference price, but 0.2 m to 5 m and coiled versions are available. Jacket color, head color, printed logo, USB plug style, pin plating and packaging artwork can all be set for an ODM program. Where the head geometry is new, our toolroom quotes the mold separately and states the cost before any tooling spend; 3,000+ tooling sets have been built since 2012 and 100+ molds remain active. Prototype runs of 1 to 50 pieces allow first-article approval, after which the volume run follows the approved sample. If you are replacing an existing supplier, send the current cable and we will match it to a sample, including the fuse specification on the drawing. All prices on this page are indicative, quoted FOB, and must be confirmed per RFQ. Unit price varies with connector, length, jacket, packaging, tooling and the compliance documentation required for the destination market. Fuse ratings and test limits are specified on the drawing and confirmed in writing before production.

Quality Control and Testing

Every cable is checked for continuity, correct pin assignment, short circuits and an intact fuse path before packing. The head is mated against a reference fixture to verify seating and pin travel, and the overmold is inspected for flash and sharp edges. Lot documentation can include insulation resistance, hi-pot results, strain-relief pull-test data and a first-article inspection report when specified. For a sealed body-contact product we recommend adding a wipe-down cycle with the actual cleaning agent and a temperature-rise check during qualification, since those are the failures that appear in the field rather than on the line. Test methods and acceptance limits are agreed in writing before production so the report matches the drawing rather than a generic checklist.

Packaging, MOQ and Lead Time

The reference price assumes bulk packing in PE bags and export cartons. Retail boxes, header cards, barcode labels, warning text and custom print are separate options. Prototype quantities of 1 to 50 pieces are available; volume pricing typically begins at 10,000 pieces and moves with the connector and tooling. Lead time is stated in the RFQ response, since it depends on whether tooling exists and on the test and documentation package for the destination market. Where a buyer sells into several markets, we can hold one approved electrical build and vary only the packaging and labeling, which keeps the unit cost stable while satisfying local requirements. For anything not covered here, use the RFQ form.

Frequently Asked Questions

Is the fuse visible on the cable? No. It is embedded inside the USB-A male plug housing, so the connector looks like a standard USB-A plug. Its rating is set per project and confirm per build.

Is the US$0.40 price fixed? No. It is an indicative FOB figure for the reference 1 m build at 10,000 pieces; all prices are confirm per RFQ and change with fuse specification, tooling, length and packaging.

Can you match an existing charger? Yes. Send the current part and we measure pitch, pin count, magnet polarity and head outline, then quote a matched build with a first article for approval.

Do you supply material compliance documents? Yes, including California Proposition 65 testing for lead and phthalates, available on request. Coverage is confirmed per build in writing before production.

What is the minimum order? Prototypes of 1 to 50 pieces are available; the reference volume tier typically starts at 10,000 pieces and is confirm per RFQ.

Related Cable Ranges

This build is part of our Low-Cost Cable Assemblies line for volume ODM programs. For broader power-lead options see DC Plug Power Cables, and for build-to-print looms see Custom Wire Harnesses. Also compare the fuse protected charging cable and the custom magnetic charging cable programs. The RFQ preparation guide lists what to send. Request a written quote through the RFQ form.